Method and device for monitoring the quality of yarns and wound packages produced by and the quality of operation of a textile machine

ABSTRACT

Bobbins spun in a ring spinning machine are conveyed sequentially to a measuring, counting and sorting device located between the ring spinning machine and an automatic winder that winds yarn from the bobbins. The measuring, counting and sorting device senses the presence of a bobbin, counts the bobbins being sensed, senses yarn and bobbin characteristics and compares the characteristics with predetermined standards. The device separates bobbins whose characteristics differ from the standard. Data regarding the operation of the spinning machine and operation of the winding machine are combined with the data obtained by the measuring, counting and sorting device and statistically evaluated for display or for controlling the production of the spinning machine and winding machine or for controlling conveyance of the packages from the winding machine.

BACKGROUND OF THE INVENTION

The present invention relates to a method and device for monitoring thequality of yarns and wound packages, and the quality of operation atproduction stations in a textile machine in which at least one ringspinning machine is combined with at least one automatic winder.

Combining ring spinning machines and automatic winders increasesefficiency and reduces operating costs, but requires automaticmonitoring and control to maintain proper operating conditions andprovide quality yarn and yarn packages. The present invention isdirected to improving such automatic monitoring to obtain enhancedproduction results.

SUMMARY OF THE INVENTION

Briefly described, the present invention provides a method of and devicefor monitoring the quality of yarns and wound packages produced and thequality of operation at production stations in a textile machine inwhich at least one ring spinning machine is combined with at least oneautomatic winder. The method includes conveying the bobbins from thering spinning machine to the winder in sequence in relation to therespective spinning stations of the ring spinning machine, andmeasuring, counting and sorting the bobbins between the ring spinningmachine and winder. The measuring includes sensing the presence of abobbin and the counting includes counting the bobbins sensed by themeasuring and determining the spinning station at which each bobbin wasspun. The measuring also includes sensing yarn and bobbincharacteristics and comparing the sensed characteristics withpredetermined standards for such characteristics. The sorting includesseparating from the bobbins being conveyed to the winder those bobbinswhose sensed characteristics differ from the predetermined standards.The method also includes evaluating the sensed characteristics inrelation to the spinning stations to determine the quality of operationat the related spinning stations.

In the device of the present invention, means for conveying the bobbinsis provided along with means for measuring, means for counting, meansfor sorting and means for evaluating, which means perform the functionsof the method described above.

Preferably, the evaluating is responsive to the measuring and countingto provide an indication of spinning stations at which those bobbinswhose sensed characteristics differ from the predetermined standard havebeen spun.

For a more complete automatic monitoring, the operation of the spinningstations may be sensed to obtain data, e.g. yarn breaks, down time,operating speeds, yarn size, yarn twist and draft, and providing datathereof, with this data then being evaluated in combination with datafrom the aforesaid measuring. This evaluation then provides anindication that can be utilized in controlling operations of themachine. This evaluating can relate to operating characteristics ofindividual spinning stations and of all the stations combined.

Similarly, sensing of the operations of the winder and providing datathereof may be included in the method of the present invention. Withthis arrangement the evaluating evaluates the winder operation data incombination with the spinning stations operation data and data from themeasuring, with the indications from the evaluation being applied foreither designating the evaluation, controlling production, controllingbobbin conveyance, or grading the wound packages. In the preferredembodiment the winder operation data is collected at the winder andtransmitted to the evaluating location. Also in the preferredembodiment, the winder operation sensing senses yarn breaks, clearercuts, thin and thick yarn locations, double yarns, tying and splicingattempts and winding head disturbances.

Also, in the preferred embodiment, the measuring includes sensing thetype of yarn on the bobbins and includes emitting an alarm signal with aspinning station designation when an incorrect type of yarn is sensed ona bobbin.

Alternatively, the sorting according to the preferred embodimentincludes predetermined separating of bobbins spun at predeterminedspinning stations with the predetermined separating being independent ofthe sensing of yarn and bobbin characteristics. With this arrangementdifferent types of yarns or yarn with different spun characteristics canbe spun in the same machine and wound separately.

In the device of the present invention, means for conveying the bobbinsis provided along with means for measuring, means for counting, meansfor sorting, means for evaluating, spinning stations operating sensingmeans, winding operation sensing means, data collecting and transmittingmeans, applying means, and alarm signal emitting means, which meansperform the functions of the method described above.

The yarn and bobbin characteristics that may be sensed in application ofthe present invention include, for example, the hairiness of the yarn,the yarn material, the form of the bobbin, or the surface of the bobbin.Those bobbins that deviate from the standards or have yarn that deviatesfrom the standards may be separated for rejection or conveyance toseparate winding stations. Also, the monitoring can be used to determinethe quality of production at individual spinning stations or in sectionsof the machine or in the machine overall.

The present invention can be utilized as described to determine qualitydeficiencies. For example, if quality deviations are evaluated asoccurring in the same section of the spinning machine or at the samespinning stations in successive bobbins, it can be concluded that thelow quality results from operation of the section or individual station.On the other hand, if the low quality is unevenly distributed throughoutthe bobbins, it is more likely that the yarn material is of unevenquality or production quality is substandard in the preparation of theyarn prior to being processed on the spinning machine.

In a more refined form of the invention, recorded measured data iscombined statistically and displayed or automatically applied to controloperation of the machine. In this manner errors and conditions whichreduce production can be determined and dealt with more rapidly andprecisely than heretofore.

In evaluating data relating to yarn breaks, down time, spinning speed(e.g. spindle rpms), yarn size, yarn twist and draft, the data can beutilized to indicate the cause or location of substandard quality. Thus,if yarn size, yarn twist and draft deviate from standard values withoutyarn breaks, down time and spinning speed deviations, then the lowquality would be primarily in the spinning stations. If on the otherhand, both categories of data deviate from standard, the problem may bein the roving that is supplied to the machine. If yarn size, yarn twistand draft are within standard quality requirements and only the yarnbreaks, down time or spinning speed deviate from standard, the problemis probably in the yarn material or roving.

It is rather infrequent that incorrect yarn material is fed to aspinning station. However, if this occurs and it is not recognizedimmediately, considerable loss of production can result. This is avoidedin the present invention by the above described sensing of incorrectyarn and emitting an alarm signal which can be used to immediately stopproduction and replacement of the supply bobbin at the designatedstation.

Other and further features and advantages of the present invention areapparent from the accompanying drawings and the following detaileddescription of the preferred embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1-5 are diagrammatic illustrations of the preferred embodiments ofthe present invention incorporated in a textile machine.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIG. 1, a textile machine is shown consisting of a ringspinning machine 2 and an automatic winder 3. The ring spinning machine2 has a large number of spinning stations, only several of which areillustrated. These are designated by the reference numerals 2.1 through2.9. The automatic winder 3 has winding stations designated by thereference numerals 3.1 through 3.6. Bobbins 4 produced by the ringspinning machine 2 are conveyed on a conveyor belt 5 in a predeterminedsequence to a measuring, counting and sorting device located between thering spinning machine 2 and the automatic bobbin winder 3. This deviceis designated in its entirety by the reference numeral 6. Cross-woundpackages 7 are produced at the winding stations 3.1 through 3.6 of theautomatic bobbin winder 3 from the bobbins supplied from the ringmachine 2.

The device 6 is a multi-function device with a counting component Z, ameasuring component M, a sorting component S, and a preparationcomponent V. The measuring component M includes a first sensing unit 8that senses a bobbin 4 on the conveyor belt 5. The counting component Zis responsive to the first sensing unit 8 to count bobbins. Themeasuring component M includes a second sensor 9 for sensing thehairiness of the windings on the bobbin. A third sensing unit 10 sensesthe form of the bobbin. A fourth sensing unit 11 senses the type of yarnmaterial on the bobbin. A fifth sensing unit 12 senses the weight of thebobbin.

The values sensed by the sensing units 9 through 12 are compared withpredetermined standard values and any bobbins whose sensedcharacteristics differ from the predetermined standards are separated bythe sorting component S along a transport path 13. Those bobbins thatare not separated are conveyed to the preparation component V where theyarn end on the bobbin is prepared in readiness for engagement in thewinder. From the preparation component V, the bobbins are conveyedsequentially in response to demand from one of the winding stations 3.1through 3.6 on a conveyor belt 14 to the demanding winding station ofthe automatic winder 3. After the yarn is removed from the bobbins inthe winding stations, the empty tubes are returned on a conveyor (notshown) back to the ring spinning machine 2 for winding of yarn thereonat the winding stations.

Operation of the spinning stations is monitored to obtain data, such asthe number of yarn breaks, the down time, the spindle rpms or spinningspeed, and this data is evaluated by a programmable computer-typeprocessor I1, which is connected by leads to the individual spinningstations 2.1 through 2.9, such as by the lead 15 from the spinningposition 2.9.

Operation of the winding stations is monitored to obtain data, such asthe number of yarn breaks, clearer cuts, thick and thin yarn locations,double yarns, tying and splicing attempts and winding stationdisruptions, and this data is evaluated by a programmable computer-typeprocessor I2, which is connected by leads to the individual windingstations 3.1 through 3.6, such as by the lead 16 from the windingposition 3.1.

The automatic winder 3 also includes for each winding station a clearerR, which determines whether the yarn is running, senses thick and thinareas in the yarn and performs clearing cuts. Each interruption of theyarn results in a stoppage of the winding station, which requiressubsequent knotting or splicing and resumption of the winding operation.Automatic knotting or splicing devices are used, but are not illustratedas they are of conventional construction. The clearers R are connectedto the individual winding stations by leads. For example, lead 17connects the winding station 3.3 to the clearer R. As the processor I2also collects the data from clearer R, it is connected to the clearer Rby lead 18. The other clearers are similarly connected.

The results of the sensing by the sensing unit 9 through 12 incomparison with the standard characteristics can be performed in themeasuring component M itself. This is the situation in the embodiment ofFIG. 1. The counting component Z sequentially counts the bobbins,including those that are sensed to be separated. Thus, a determinationcan be made based on the counting result regarding the section of thering spinning machine 2 in which bobbins are produced withcharacteristics different from the standard. The information collectedin the processor I1 also provides for evaluation of the bobbin and yarnquality as well as the quality of production of the individual spinningstations. The data collected in the processor I2 provides evaluationregarding the quality of the cross-wound packages and the quality of thewinding operations at the individual winding stations.

The evaluation of the sensed data may be performed other than at thedevice 6 or measuring component M. For example, in FIG. 2, theevaluating function is performed by the processor I2, for which purposethe sensing units 9 through 12 and the counting and sorting componentsare connected by lead 19 to the processor I2. In this arrangement, thedata can be evaluated and signals generated to indicate conditions orcontrol the operation of the spinning and winding stations.

Rather than using the processor I2, the processor I1 of the ringspinning machine could be used for this same purpose, for example, by alead 20 from the sensing units 9 through 12 and measuring, counting andsorting device 6 to the processor I1. Alternatively, both processors I1and I2 could be connected to the measuring, counting and sorting device6 to distribute the functions of evaluating between the two processorsand used in combination with data from the machine with which it isassociated.

A modified embodiment is illustrated in FIG. 3 where the data from themeasuring, counting and sorting device 6 is connected by lead 19,processor I2 and leads 21 and 22 to a central evaluating unit in theform of a processor I3. The data collected by the processor I1 of thering spinning machine 2 is similarly connected by lead 23 to theprocessor I3. Processor I2 also supplies the data collected from theautomatic winder 3. In this arrangement the evaluation of the dataoccurs primarily in processor I3. Display devices 27 and 28 and messagedevices 29 and 30 are included in the processor I3.

A further embodiment is illustrated in FIG. 4, which differs from theembodiment of FIG. 3 primarily in that the processor I3 of FIG. 4 iscapable of controlling by lead 24 the automatic winding operation and bylead 26 the automatic spinning operation. This arrangement utilizesevaluation of data regarding yarn breaks, running times, spindle rpms ofthe spinning machine, package weight, hairiness, diameter and form ofthe bobbins, and yarn position of the bobbins passing through themeasuring, counting and sorting device, data regarding Uster standards,clearer adjustments, splicer times, improper joinings, winding speed,clearer cuts, and yarn breaks at the winding stations of the winder.Signals may be transmitted in both directions through leads 21, 22 and23.

Referring to FIG. 5, a variation of the embodiment of FIG. 3 isillustrated in which data can be transmitted by lead 26 to a computer 32that controls a transport system 31 that transports the cross-woundpackages 33, 34, 35 and 36 produced on the automatic winder. Thistransport is accomplished by a carrier 37 riding on a track 38 in thedirection of the arrow 39. The computer 32 controls the operation of thetransport means 31 by information from the processor I3 regarding theyarn type and package quality of the individual packages. High qualitypackages can be automatically separated from low quality packages inthis manner, for example, according to commercial grades. Differences inquality can result from the length of yearn on the package, the weightof the package, the package size or the winding density. The lattercharacteristic is of particular significance in packages that are to bedyed. Also, loosely wound packages can be processed further separatelyfrom more tightly wound packages. Thus, the disadvantage of having amixture of unequal packages can be avoided by this arrangement.

The processor I3 can perform a statistical evaluation and the data andevaluation can be printed out on a printer 40 connected to the processorI3.

It will therefore be readily understood by those persons skilled in theart that the present invention is susceptible of a broad utility andapplication. Many embodiments and adaptations of the present inventionother than those herein described, as well as many variations,modifications and equivalent arrangements will be apparent from orreasonably suggested by the present invention and the foregoingdescription thereof, without departing from the substance or scope ofthe present invention. Accordingly, while the present invention has beendescribed herein in detail in relation to its preferred embodiment, itis to be understood that this disclosure is only illustrative andexemplary of the present invention and is made merely for purposes ofproviding a full and enabling disclosure of the invention. The foregoingdisclosure is not intended or to be construed to limit the presentinvention or otherwise to exclude any such other embodiments,adaptations, variations, modifications and equivalent arrangements, thepresent invention being limited only by the claims appended hereto andthe equivalents thereof.

We claim:
 1. A method of monitoring the quality of yarns and woundpackages produced and the quality of operation at production stations ina textile machine in which at least one ring spinning machine iscombined with at least one automatic winder, said method comprisingconveying said bobbins from said ring spinning machine to said winder insequence in relation to the respective spinning stations of said ringspinning machine, measuring, counting and sorting said bobbins betweensaid spinning machine and said winder, said measuring includes sensingthe presence of a bobbin, said counting includes counting the bobbinssensed by said measuring and determining the spinning station at whicheach bobbin was spun, said measuring further includes sensing yarn andbobbin characteristics and comparing said sensed characteristics withpredetermined standards for said characteristics, said sorting includesseparating from the bobbins being conveyed to the winder those bobbinswhose sensed characteristics differ from said predetermined standards,and evaluating the sensed characteristics in relation to the spinningstations to determine the quality of operation at the related spinningstations.
 2. A method according to claim 1 and characterized further inthat said evaluation is responsive to said measuring and counting toprovide an indication of spinning stations at which those bobbins whosesensed characteristics differ from the predetermined standard have beenspun.
 3. A method according to claim 1 and characterized further bysensing the operation of the spinning stations and providing datathereof, evaluating the sensed spinning stations operation data incombination with data from said measuring, and providing an indicationof the evaluation.
 4. A method according to claim 3 and characterizedfurther in that said spinning stations operation sensing includessensing one or more of yarn breaks, down time, operating speeds, yarnsize, yarn twist and draft.
 5. A method according to claim 4 andcharacterized further by evaluating said spinning stations operationsensing to provide data regarding the operating characteristics ofindividual spinning stations and of all the stations combined.
 6. Amethod according to claim 3, 4 or 5 and characterized further by sensingthe operation of the winder and providing data thereof, in that saidevaluating evaluates said winder operation data in combination with saidspinning stations operation data and data from said measuring, and byapplying said indication for at least one of designating the evaluation,controlling production, controlling bobbin conveyance, or grading thewound packages.
 7. A method according to claim 6 and characterizedfurther by collecting said winder operation data at said winder andtransmitting said data to said evaluating.
 8. A method to claim 7 andcharacterized further in that said winder operation sensing senses yarnbreaks, clearer cuts, thick or thin yarn locations, double yarns, tyingand splicing attempts and winding head disturbances.
 9. A methodaccording to claim 6 and characterized further in that said winderoperation sensing senses yarn breaks, clearer cuts, thick or thin yarnlocations, double yarns, tying and splicing attempts and winding headdisturbances.
 10. A method according to claim 1 and characterizedfurther in that said measuring includes sensing the type of yarn on thebobbins, and by emitting an alarm signal with a spinning stationdesignation when an incorrect type of yarn is sensed on a bobbin
 11. Amethod according to claim 1 and characterized further in that saidsorting includes predetermined separating of bobbins spun atpredetermined spinning stations with said predetermined separating beingindependent of said sensing of yarn and bobbin characteristics.
 12. Adevice for monitoring the quality of yarns and wound packages producedand the quality of operation at production stations in a textile machinein which at least one ring spinning machine is combined with at leastone automatic winder, said device comprising means for conveying saidbobbins from said ring spinning machine to said winder in sequence inrelation to the respective spinning stations of said ring spinningmachine, means for measuring, means for counting and means for sortingsaid bobbins between said spinning machine and said winder, saidmeasuring means sensing the presence of a bobbin, said counting meanscounting the bobbins sensed by said measuring and determining thespinning station at which each bobbin was spun, said measuring meanssensing yarn and bobbin characteristics and comparing said sensedcharacteristics with predetermined standards for said characteristics,said sorting means separating from the bobbins being conveyed to thewinder those bobbins whose sensed characteristics differ from saidpredetermined standards, and means for evaluating the sensedcharacteristics in relation to the spinning stations to determine thequality of operation at the related spinning stations.
 13. A deviceaccording to claim 12 and characterized further in that said evaluatingmeans is responsive to said measuring means and counting means toprovide an indication of spinning stations at which those bobbins whosesensed characteristics differ from the predetermined standard have beenspun.
 14. A device according to claim 12 and characterized further bymeans sensing the operation of the spinning stations and providing datathereof, means evaluating the sensed spinning stations operation data incombination with data from said measuring means, and providing anindication of the evaluation.
 15. A device according to claim 14 andcharacterized further in that said spinning stations operation sensingmeans senses one or more of yarn breaks, down time, operating speeds,yarn size, yarn twist and draft.
 16. A device according to claim 15 andcharacterized further by means for evaluating sensing by said spinningstations operation sensing means and providing data regarding theoperating characteristics of individual spinning stations and of all thestations combined.
 17. A device according to claim 14, 15 or 16 andcharacterized further by means for sensing the operation of the winderand providing data thereof, in that said evaluating means evaluates saidwinder operation data in combination with said spinning stationsoperation data and data from said measuring means, and by means forapplying said indication for at least one of designating the evaluation,controlling production, controlling bobbin conveyance, or grading thewound packages.
 18. A device according to claim 17 and characterizedfurther by means for collecting said winder operation data at saidwinder and transmitting said data to said evaluating means.
 19. A deviceaccording to claim 18 and characterized further in that said winderoperation sensing means senses yarn breaks, clearer cuts, thick or thinyarn locations, double yarns, tying and splicing attempts and windinghead disturbances.
 20. A device according to claim 17 and characterizedfurther in that said winder operation sensing means senses yarn breaks,clearer cuts, thick or thin yarn locations, double yarns, tying andsplicing attempts and winding head disturbances.
 21. A device accordingto claim 12 and characterized further in that said measuring meanssenses the type of yarn on the bobbins, and by means for emitting analarm signal with a spinning station designation when an incorrect typeof yarn is sensed on a bobbin.
 22. A device according to claim 12 andcharacterized further in that said sorting means separates bobbins spunat predetermined spinning stations independent of the sensed of yarn andbobbin characteristics.